A wall assembly is manufactured for supporting an exterior covering of a structure. The wall assembly includes a frame assembly including a top member and a bottom member spaced from the top member. The frame assembly further includes a plurality of vertical members spaced from each other and coupled to and extending between the top and bottom members. The plurality of vertical members each have an exterior surface configured to face an exterior of the structure. A rigid foam layer is directly coupled to the exterior surface of the plurality of vertical members. A sheathing layer is coupled to the rigid foam layer opposite the plurality of vertical members with the sheathing layer configured to receive the exterior covering.

Certain exemplary embodiments can provide a wall frame comprising a top plate, a bottom plate, a first end column, a second end column, a plurality of studs, and a plurality of purlins. Each of the plurality of purlins is an edge of a pair of cells, the pair of cells having edges comprising three edges that comprise one or more of a part of the top plate, a part of the bottom plate, a part of the first end column, a part of the second end column, a part of the plurality of studs, and another of the plurality of purlins.

A partition for a building structure comprises a support frame and a plasterboard affixed to the support frame. The support frame comprises a plurality of elongate timber members. The plasterboard comprises a gypsum matrix having fibres embedded therein in an amount of at least 1 wt % relative to the gypsum, as well as a polymeric additive that is present in an amount of at least 1 wt % relative to the gypsum.

A wall element including upper and lower elements at upper and lower edges. A first side element extending along the first side, a second side element extending along the second side and a substantially rectangular board are present. The upper and lower elements include a first edge coinciding with the first side and a second edge coinciding with the second side, wherein the first and second edges are arranged in an angle with respect to a plane perpendicular to the outer surface, the angle lies within the interval 20°-45°, and the first and second side elements extending parallel to the plane, perpendicular to the board and having a total extension corresponding to the extension of the upper and the lower element in the plane, wherein the first side element bear against the plate and the second side element extend from the inside of the wall element.

Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly; a sheathing layer; a closed cell inner foam layer for coupling the layer to the frame assembly; and an outer fiberboard. Also described herein is a method of manufacturing the wall assembly.

Described herein is a wall assembly for use in walls of energy efficient residential or commercial buildings which can provide improved thermal resistance, moisture resistance and structural capacity. The wall assembly includes a frame assembly; a laminated outer sheathing layer; and a closed cell inner foam layer for coupling the layer to the frame assembly. Also described herein is a method of manufacturing the wall assembly.

A method of manufacturing building panels includes assembling a frame of a building panel. The frame defines at least one cavity and at least one injection aperture in fluid communication with the at least one cavity. The method also includes positioning the frame on one of a base and a shelf of a multi-panel consolidation device having a plurality of shelves, with the shelves being in an expanded configuration, and at least substantially enclosing the at least one cavity. The method also includes forcing the shelves of the multi-panel consolidation device into a collapsed configuration, and injecting an expandable polymer through the at least one injection aperture into the at least one cavity. The method further includes forcing the shelves into an expanded configuration after a predetermined period of time selected to permit the expandable polymer to form a foam bonded to the frame.

An open cell spray polyurea foam for use in an insulation layer in a wall structure may include a polyurea. The polyurea may be a reaction product of an isocyanate compound and water. The open spray polyurea foam may also include a filler. The majority of the filler may exist in the spray foam formulation as an unreacted first fire retardant. The spray foam formulation may further comprise a second fire retardant, and the insulation layer may exhibit a fire retardancy sufficient to pass Appendix X and/or ASTM E-84.

A system and method for assembling framing assemblies for use as ceiling or floor structures of modular building units using automation are disclosed. The framing assemblies include trusses that are attached at the lateral edges thereof by a joist including at least one layer of dimensional lumber to form a substantially rigid framework. Cover panels are positioned over and attached to an inner surface of the framing assembly.

A panel for forming part of a partition is disclosed. The partition may, for example, be a roof, a wall or a floor of a building. The panel comprises: a central panel; two support members; and a resiliently compressible portion. The two support members are disposed on opposed sides of the central panel, each of the two support members extending generally perpendicularly to a plane of the central panel. The resiliently compressible portion is arranged between the two support members such that a distance between the two support members can be reduced by compressing the resiliently compressible portion.